Logistics Center (GVZ)
Logistics processes for automotive manufacturers are becoming increasingly complex due to the enormous variety of model versions and the creation of worldwide networks for production and procurement. Suitable approaches are required to manage these processes. One such solution entails consolidating material flows in industrial parks. Systems and modules are assembled outside the carmaker’s factory gates and delivered to the assembly line just in sequence. This is the approach adopted by the Logistics Center at Audi’s Ingolstadt site.
The Logistics Center, which opened in 1995, has two investors and owners: IFG Ingolstadt (a company fully owned by the city of Ingolstadt) and LGI GmbH (a joint subsidiary of IFG Ingolstadt and AUDI AG). The initial construction phase consisted of two buildings with a total floor space of 30,000 square meters. Meanwhile, the Logistics Center occupies a site of 118 hectares, on which 14 buildings stand with a floor space of 368,000 square meters. The 15th building, Hall T, will be opened shortly.
Environmental awareness, fast information flows and short transportation distances are the most important aspects of modern logistics. So the fact that the Logistics Center is located just outside the factory gates is no coincidence, but the result of traffic studies, and it also benefits the city of Ingolstadt. The main advantages of the Logistics Center for Audi are security of supply, the ability to deal with complex processes, and reduced logistical costs consisting of transport, packaging, inventory and IT costs. Besides reducing environmental pollution, for example due to fewer trucks needed to transport freight, the Logistics Center also boosts Ingolstadt’s economy and creates new jobs.
Module suppliers manufacture their products just in sequence in so-called assembly centers and are responsible for delivering them to the assembly lines. Materials are delivered directly to the assembly lines by electric tractors and trailers. These vehicles make the journey across the fully covered 415-meter bridge directly to the production area around the clock, approximately 2,500 times a day. 14 external suppliers and service providers currently supply Audi via the Logistics Center. They are primarily suppliers who manufacture highly varied, complex components and systems, and who place the highest requirements on their control systems.
The Logistics Center has two consolidation centers dealing with material handling for the Audi plants in Győr and Brussels and for CKD (completely knocked-down) packaging. Halls J and K accommodate Audi Tradition, the Service Training Center for Audi’s customer service, and the Logistics Center hotel. A large new consolidation center was established at the Logistics Center in December 2010. On an area of 35 hectares and with a floor space of currently 103,000 square meters, assembly components previously stored temporarily in various areas inside and outside the plant are now handled centrally in this building.
Complexity is steadily increasing at the Ingolstadt site, along with logistical challenges. This is due to new generations of vehicles, additional models in the product portfolio, the high degree of customizability, and especially the ever-shorter transition periods. This is why Audi requires additional space near its plant and the Logistics Center’s new Hall T will help meet this need. Components will be sequenced there and assembled as needed to supply the assembly lines. A total of about 4,500 people currently work at the Logistics Center and Hall T will create new jobs. It will thus contribute to job security and consolidate Audi’s position in the region.
* The fuel consumption and emissions values of all models mentioned in the text and of all models available on the German market are listed in the last chapter of this basic information.